Professional Documents
Culture Documents
REPORT OF INVESTIGATIONS/1997
By
Jeffrey L. Kohler
CONTENTS
Page
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyses of high-voltage longwall power systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Approach to system analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Factors affecting short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor starts and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor-start evaluations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field tests of mine motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data acquisition hardware and software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor waveform analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor-start phase-angle observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor-start detection scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prototype circuit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary and conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix.Circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ILLUSTRATIONS
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A-1.
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ampere
ms
millisecond
hp
horsepower
MVA
megavolt ampere
Hz
hertz
second
km
kilometer
volt
kV
kilovolt
percent
kVA
kilovolt ampere
degree
meter
Mention of any company name or product does not constitute endorsement by the National Institute for Occupational Safety and Health.
To receive other information about occupational safety and health problems, call 1-800-35-NIOSH (1-800-356-4674), or visit the
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Michael R. Yenchek,1 James C. Cawley,2 Jeffrey Shawn Peterson,1 and Jeffrey L. Kohler3
ABSTRACT
The Pittsburgh Research Center (PRC)4 investigated how the starting of induction motors may cause nuisance
tripping of short-circuit protection on coal mine power systems. This research had a threefold purpose: (1) to
determine the range of typical values for power system characteristics that affect short circuits and motor starts on
high-voltage longwalls, (2) to identify how motor-start waveforms differ from those for short circuits, and (3) to
devise a method to provide short-circuit protection without intentional time delays to account for motor starts.
Distribution voltage, transformer impedance, power center location, and motor size were found to critically influence
the magnitude of short-circuit and motor-start currents on high-voltage longwalls. An attribute of motor-start
signatures that distinguished them from short circuits was the relatively large phase angle between voltage and
current. Electronic circuitry was designed to detect phase angles and react to momentarily disable circuit breaker
action for motor starts. A prototype was successfully evaluated with an induction motor in the laboratory. By
minimizing intentional time delays in short-circuit protection, this technology will help ensure that surface
temperatures of energized electrical apparatus will not exceed gas or dust ignition thresholds when such faults occur.
Electrical engineer, Pittsburgh Research Center, National Institute for Occupational Safety and Health, Pittsburgh, PA.
Supervisory electrical engineer, Pittsburgh Research Center, National Institute for Occupational Safety and Health, Pittsburgh, PA.
3
Associate professor, Department of Mineral Engineering, The Pennsylvania State University, University, PA.
4
This research originated under the U.S. Bureau of Mines prior to transferring to the National Institute for Occupational Safety and Health in 1996.
2
INTRODUCTION
On August 27, 1992, the Mine Safety and Health Administration (MSHA) published proposed rules for high-voltage
electrical equipment used in longwall face areas of underground
5
coal mines [57 Fed. Reg. 39036 (1992)]. The intent of these
regulations is to reduce the likelihood of fire, explosion, and
shock hazards by citing requirements for electrical enclosures,
circuit protection, testing, and personnel protection.
The
operational limits for short-circuit protective devices are proposed
within section 75.814 of these rules.
Short-circuit protection for electrical apparatus in underground
coal mines is critical. When different phases of an electrical circuit
inadvertently come in contact, thousands of amperes may flow.
Currents of this magnitude can cause explosions and fires if
permitted to exist even for periods as brief as 1 s. The thermal
2
energy expended is directly related to I t [ANSI/IEEE standard
242, 1986]. Consequently, protective device settings must be
specified with a maximum sensitivity to current (I) and a minimum reaction time (t).
Unfortunately, extremely low current settings may interfere
with mining operations by inadvertently reacting to normal
transient events, such as the starting of motors. In response, the
proposed MSHA rules specify maximum time delays for shortcircuit protection of cables extending from the power center to
motor starters. In the future, the trend toward higher efficiency
motors
with
greater
peak
starting
currents
may
BACKGROUND
Protection against short circuits on mine power circuits is
typically provided by molded-case circuit breakers or vacuum
interrupters. The current magnitude thresholds or settings at which
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these devices operate are specified either by regulation [30 CFR
75.601 (1992)] for low- and medium-voltage circuits or through
the MSHA approval process [Boring and Porter 1988] for highvoltage longwalls. The initial inrush currents, demanded by large
induction motors starting across the line, may exceed these settings
and activate the protection devices needlessly. Consequently, to
prevent nuisance tripping of the short-circuit protection, it is
desirable to seek a means to momentarily disable or inhibit the
protection device activation for a finite period following motor
energization.
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MOTOR-START EVALUATIONS
The nature of how the starting of induction motors may cause
nuisance tripping of short-circuit protection has been analyzed.
Electrical safety can be enhanced if the circuit-protection device
recognizes and reacts only to short circuits. To devise a means to
discriminate between motor starts and short circuits, one must first
investigate how the waveforms of each event differ. Any
distinguishing characteristics may then be keyed upon through the
design of sensing circuitry. Accordingly, it was decided to record
the voltage and current waveforms of mine induction motors of
various voltages and evaluate their salient characteristics.
FIELD TESTS OF MINE MOTORS
To gain insight into motor-start signatures, field tests of a
variety of mine motors were conducted. These included motors
with application in both longwall and continuous mining, with
voltages ranging from 440 to 4,160 V and power ratings
ACKNOWLEDGMENT
The authors acknowledge the assistance of Elio L. Checca of the
MSHA Technical Support Group, Pittsburgh, PA, who
REFERENCES
ANSI/IEEE standard 141 [1993]. Recommended practice for electric power
distribution for industrial plants (IEEE red book). Institute of Electrical and
Electronics Engineers, Inc.: New York, NY.
ANSI/IEEE standard 242 [1986]. IEEE recommended practice for protection
and coordination of industrial and commercial power systems (IEEE buff book).
Institute of Electrical and Electronics Engineers, Inc.: New York, NY, p. 344.
Boring CM, Porter KJ [1988]. Criteria for approval of mining equipment
incorporating on-board switching of high-voltage circuits. In: Proceedings of the
Ninth WVU Mining Electrotechnology Conference. Morgantown, WV: West
Virginia University, pp. 267-274.
CFR. Code of Federal regulations. Washington, DC: U.S. Government
Printing Office, Office of the Federal Register.
DeCastro JE, Beck RT, Cai C, Yu L [1995]. Stall protection of large
induction motors. In: IEEE Transactions on Industry Applications. Vol. 31,
No. 5, pp. 1159-1166.
57 Fed. Reg. 39036 [1992]. Mine Safety and Health Administration:
proposed rules.
Huenig WC [1982]. Calculating short-circuit currents with contributions from
induction motors. In: IEEE Transactions on Industry Applications. Vol. IA-18,
No. 2, pp. 85-92.
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APPENDIX.CIRCUIT DESCRIPTION
The circuit described here (figure A-1) can monitor the current
and voltage waveforms for one phase of a three-phase circuit. A
suitable potential transformer is required for a phase-to-phase
voltage measurement.
Referring to figure A-1, the 120-V
secondary voltage is fed to pin 5 of IC1 through R11. IC1
develops an output pulse on pin 4 each time the input voltage goes
through zero. Similarly, a current transducer supplies a 120-V
signal that corresponds to the magnitude of the line current to pin
5 of IC7 through R12. Line current magnitude is also measured by
IC's 11 and 12, which are described later. Pin 4 of IC12 develops
an output pulse during each current zero crossing.
To accurately measure electrical degrees during each half-cycle,
a crystal-controlled complementary-metallic-oxide-semiconductor
oscillator, producing clock pulses at 32,768 Hz, was selected as a
time reference. There are 21,600 (60 Hz 360 electrical
degrees/cycle) electrical degrees per second. In a full 60-Hz cycle,
there are 546 (32,768 clock cycles/second (1/60)
second/electrical cycle) clock cycles. By proportion, the number
of clock cycles corresponding to a desired time delay (or phase
angle) between voltage and current waveforms is shown below:
Electrical
degrees . . . .
150 120
70
60
45
30
20
10
Clock
cycles . . . . . .
91
69
46
31
16
90
80
The voltage zero-crossing pulse from IC1 pin 4 sets the set-reset
flip-flop, IC2. Once set, IC2 enables IC3 to gate clock pulses from
IC10 into the binary counter, IC4. IC4 counts the clock pulses
until a current zero-crossing pulse is received from IC7 pin 4.
When the current zero-crossing pulse is generated, it resets the setreset flip-flop, IC2, and resets the counter, IC4, to zero. In
addition, when IC2 is reset, the flow of clock pulses to the counter,
IC4, is stopped until a voltage zero-crossing pulse begins the
process over again during the next half-cycle.
11
12